msd servo drive compact operation manual

moog

MSD Servo DriveCompact

Operation Manual

Servo drive2.0 A to 8 A

moog MSD Servo Drive Compact Operation Manual

MSD Servo Drive Compact High-Performance Drives

The modularity of the MSD Servo Drive Compact guarantees you optimum integration into the machine process. Whether in high-speed fieldbus communication with the central multi-axis machine drive or with distributed programmable Motion Control intelligence in the servo drive, the MSD Servo Drive Compact is a master of both.

MSD Servo Drive Compact Operation Manual

Id no.: CA97555-001, Rev. 3.0

Date: 06/2012

Applicable as from firmware version: V0.25

The German version is the original of this Operation Manual.

Technical alterations reserved

The contents of our documentation have been compiled with greatest care and in compliance with our present status of information.

Nevertheless we would like to point out that this document cannot always be updated parallel to the technical further development of our products.

Information and specifications may be changed at any time. For information on the latest version please refer to [email protected]..

C4 C3 C2

moog MSD Servo Drive Compact Operation Manual 3

Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

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How to use this document

Dear user,

We are happy that you have made a decision in favour of a product from Moog GmbH. In order to be able to start using your new MSD Servo Drive Compact quickly and without problems, we ask you kindly to read this Operation Manual thoroughly beforehand.

Step Action Comment

1. This Operation Manual will enable you to install and commission the MSD Servo Drive Compact system very quickly and easily.

Quick-start guide

2. Simply follow the step-by-step tables in the chapters. Off you go!

11 Safety

22 Mechanical installation

33 Electrical installation

44 Commissioning

55 Diagnostic

66 Safe Torque Off (STO)

AA Appendix

Glossary


Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

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Order code

The order designation G394-xxx-xxx-xxx informs you about the corresponding variant of the drive delivered to you. The significance of the individual characters of the order designation is given in the following order code. You will find the complete order code with all values in the MSD Servo Drive Ordering Catalog.

G394 - - -

Rated current

Option 1 (Communication)

Option 2 (Technology)

Option 3 (Safety)

Option 4 (Function package)

Variants

Fig. 0.1 MSD Servo Drive Compact order code

Rating plateOn rating plates of the MSD Servo Drive Compact you will find the serial number, from which you can identify the date of manufacture based on the following key. For the location of the rating plate on the MSD Servo Drive Compact refer to Fig. 3.1 on page 14.

Model:: G394-030-210-001

In: 230 V AC 3ph, 50/60 Hz4,0 A

0-230 V AC 3ph, 0-400 Hz3,0 A

Out:

MOOGD-71034 Böblingenwww .moog.com/industrialMade in Germany

S/N : D116605 Rev. A

ID : JJWWxxxxx

Year of production

Week of production

Fig. 0.2 MSD Servo Drive Compact hardware name plate

Supply package

The supply package includes:

•MSD Servo Drive Compact

• Terminal kit for control and power terminals (depending on device power and variant)

• Set with shield connecting plates and fixing material

• Product DVD


Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

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Pictograms

To provide clear guidance, this Operation Manual uses pictograms. Their meanings are set out in the following table. The pictograms always have the same meanings, even where they are placed without text, such as next to a connection diagram.

Warnings (see also section 1.1)

! ATTENTION! Misoperation may result in damage to the drive or malfunctions.

DANGER FROM ElECTRICAl TENSION! Improper behaviour may endanger human life.

DANGER FROM ROTATING PARTS! Drive may start up automatically.

Hints & Tips

NOTE: Useful information or reference to other documents

1. STEP: Action in a sequence of multiple actions.


Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

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Space for personal notes


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

Table of contents

1 Safety ..................................................................................... 91.1 For your safety ........................................................................................................9

1.1.1 Read the Operation Manual first! ................................................................9

1.1.2 Warning symbols .........................................................................................10

1.2 Intended use ...........................................................................................................10

1.3 Responsibility ..........................................................................................................10

2 Mechanical installation ............................................................112.1 Notes for operation .................................................................................................11

2.2 Wall mounting ........................................................................................................11

3 Installation ............................................................................. 133.1 Notes for installation ...............................................................................................13

3.2 layout .....................................................................................................................14

3.3 Connection diagram ...............................................................................................15

3.4 Effective EMC installation .......................................................................................16

3.4.1 Interference immunity of drives ...................................................................16

3.4.2 Specimen setup ...........................................................................................16

3.5 Connection PE conductor .......................................................................................19

3.6 Electrical isolation concept ......................................................................................20

3.7 Connection of supply voltage .................................................................................21

3.7.1 Connection of control supply (+24 V DC) .....................................................21

3.7.2 Connection of mains supply C2 and C3 .......................................................21

3.7.3 Connection of mains supply C4 ...................................................................22

3.8 Control connections ................................................................................................24

3.8.1 Specification of control connections ............................................................24

3.8.2 Connection of motor brake X13...................................................................25

3.9 Specification of Ethernet interface ..........................................................................26

3.10 Option 1 .................................................................................................................26

3.11 Option 2 .................................................................................................................26

3.12 Encoder connection ................................................................................................27

3.12.1 Encoder connection of the synchronous motors ..........................................27

3.12.2 Matching motor - encoder cable - drive connection .....................................27

3.12.3 Ready made-up encoder cables ...................................................................28

3.12.4 Resolver connection X6 ...............................................................................28

3.12.5 Connection for high-resolution encoder ......................................................29

3.13 Motor connection ...................................................................................................30

3.13.1 Connection of the servo motors ..................................................................30

3.13.2 Ready made-up motor cable ........................................................................31

3.13.3 Switching in the motor cable .......................................................................32

3.14 Braking resistor (RB) ................................................................................................32

3.14.1 Protection in case of braking chopper fault..................................................32

3.14.2 Design with integrated braking resistor (C3 + C4) ........................................32

3.14.3 Connection of an external braking resistor ..................................................34

4 Commissioning ...................................................................... 354.1 Notes for operation .................................................................................................35

4.2 Initial commissioning ...............................................................................................35

4.2.1 Switching on control supply .........................................................................36

4.2.2 Connection between PC and servo drive .....................................................36

4.2.3 Parameter setting ........................................................................................36

4.2.4 Drive control with Moog DriveADministrAtor 5 ..............................................36

4.3 Serial commissioning ...............................................................................................38

4.4 Integrated control unit ............................................................................................38

4.4.1 Function of buttons T1 and T2 .....................................................................39

4.4.2 Display .........................................................................................................39

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moog MSD Servo Drive Compact Operation Manual

4.4.3 Parameter menu (PA) ...................................................................................40

4.4.4 Ethernet IP-address menu (IP) ......................................................................40

4.4.5 Fieldbus address menu (Fb) ..........................................................................42

5 Diagnostics ............................................................................ 435.1 Device states ...........................................................................................................43

5.2 Error display ............................................................................................................43

5.3 Error codes ..............................................................................................................43

5.4 Helpline/Support & Service .....................................................................................44

6 Safe Torque Off (STO) ............................................................ 45

A Appendix ............................................................................... 47A.1 Current capacity of servo drives ..............................................................................47

A.2 Technical data MSD Servo Drive Compact ...............................................................49

A.3 Ambient conditions .................................................................................................51

A.4 Ul certification .......................................................................................................52

Glossary ......................................................................................... 53


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

1 Safety

1.1 For your safetyThe instructions set out below should be read through prior to initial commissioning in order to prevent injury and/or damage to property. The safety instructions must be followed at all times.

ATTENTION! The MSD Servo Drive Compact‘s “Safe Torque Off (STO)” safety function must be approved by the TÜV-Rheinland accredited certification body. This certification is currently still in preparation. Conformance to parts of EN ISO 13849-1, EN 62061, EN 61800-5-1 and EN 61508 is ensured.

!

1.1.1 Read the Operation Manual first!

1. Read the Operation Manual first!• Follow the safety instructions!

• Refer to the user information!

Electric drives are dangerous:• Electrical voltages of 230 V to 480 V

Dangerously high voltages of ≥ 50 V may still be present 10 minutes after the power is cut (capacitor charge). So check that the power has been cut!

• Rotating parts

• Hot surfaces

Protection against magnetic and/or electromagnetic fields during installation and operation.• Persons fitted with heart pacemakers, metallic implants and hearing aids

etc. must not be allowed access to the following areas:

− Areas where drive systems are installed, repaired and operated.

− Areas where motors are installed, repaired and operated. Motors with permanent magnets pose a particular hazard.

NOTE: If it is necessary to access such areas, suitability to do so must be determined before hand by a doctor.

Your qualification:• In order to prevent personal injury or damage to property, only

personnel with electrical engineering qualifications may work on the device.

• The said qualified personnel must be familiar with the contents of the Operation Manual (cf. IEC 364, DIN VDE 0100).

• Awareness of national accident prevention regulations (e.g. BGV A3 in Germany)

During installation observe the following instructions:• Always comply with the connection conditions and technical

specifications.

• Comply with the standards for electrical installations, such as regarding wire cross-section, grounding lead and ground connections.

• Do not touch electronic components and contacts (electrostatic discharge may destroy components).

Table 1.1 Safety instructions


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

1.1.2 Warning symbolsThe safety instructions detail the following hazard classes. The hazard class defines the risk posed by failing to comply with the safety notice.

Warning symbols General explanationHazard class to ANSI Z 535

! ATTENTION! Misoperation may result in damage to the drive or malfunctions.

Serious injury or damage to property may occur.

DANGER FROM ElECTRICAl TENSION! Improper behaviour may endanger human life.

Death or serious injury will occur.

DANGER FROM ROTATING PARTS! Drive may start up automatically.

Death or serious injury will occur.

Table 1.2 Explanations of warning symbols

1.2 Intended useMSD Servo Drive Compact drives are components designed solely for vertical installation in stationary electrical systems or machines.

When installed in machines the commissioning of the drive (i.e. start-up of intended operation) is prohibited, unless it has been ascertained that the machine fully complies with the provisions of the Machinery Directive 2006/42/EC; compliance with EN 60204 is mandatory.

Commissioning (i.e. start-up of intended operation) is only permitted when strictly complying with the EMC Directive (2004/108/EC).

The MSD Servo Drive Compact conforms to the low Voltage Directive 2006/95/EC.

The drives fulfill the demands of the harmonized product standard EN 61800-5-1.

If the drive is used for special applications, such as in areas subject to explosion hazard, the required standards and regulations (e.g. EN 50014, “General provisions” and EN 50018, “Flameproof housing”) must always be observed.

Repairs may only be carried out by authorized repair workshops. Unauthorized opening and incorrect intervention could lead to death, physical injury or material damage. The warranty provided by Moog GmbH would thereby be rendered void.

NOTE: Deployment of the drives in non-stationary equipment is classed as non-standard ambient conditions, and is permissible only by special agreement.

1.3 ResponsibilityElectronic devices are fundamentally not fail-safe. The company setting up and/or operating the machine or plant is itself responsible for ensuring that the drive is rendered safe if the device fails.

In the section on “Electrical equipment of machines” the standard EN 60204-1/ DIN VDE 0113 “Safety of machines” stipulates safety requirements for electrical controls. They are intended to protect personnel and machinery, and to maintain the function capability of the machine or plant concerned, and must be observed.

The function of an emergency off system does not necessarily have to cut the power supply to the drive. To protect against danger, it may be more beneficial to maintain individual drives in operation or to initiate specific safety sequences. Execution of the emergency stop measure is assessed by means of a risk analysis of the machine or plant, including the electrical equipment in accordance with EN ISO 14121 (previously DIN EN 1050), and is determined in accordance with EN ISO 13849-1 (previously DIN EN 954-1), “Safety of machines - Safety-related parts of controls” by selecting the circuit category.


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

2 Mechanical installation

2.1 Notes for operation

!

Please strictly avoid ...

• penetration of damp into the device;

• aggressive or conductive substances in the immediate vicinity;

• drill chippings, screws or foreign bodies dropping into the device;

• ventilation openings being covered over, as otherwise the device may be damaged.

Note the following points:

•Cooling air must be able to flow through the device without restriction.

• For mounting in switch cabinets with convection (= heat loss is discharged to the outside via the cabinet walls), always fit an internal air circulation fan.

• The backing plate must be well grounded.

• The device is designed only for vertical installation in switch cabinets. The switch cabinet must as a minimum provide IP4x protection.

!ATTENTION! According to EN ISO 13849-2 the switch cabinet must have IP54 protection or higher when using the STO (Safe Torque OFF) safety function.

• To attain the best result for EMC-compatible installation you should use a chromated or galvanized backing plate. If backing plates are varnished, remove the coating from the contact area. The devices themselves have an aluminium back panel.

•Maximum pollution severity 2.

Further information on environmental conditions can be found in the appendix.

2.2 Wall mounting

Step Action Comment

1. Mark out the position of the tapped holes on the backing plate.

Cut a tap for each fixing screw in the backing plate.

Dimensional drawings/hole spac-ing - see table 2.2, Fig. 2.1 and Fig. 2.2

The tapping area will provide you with good, full-area contact.

2. Mount the servo drive vertically on the backing plate.

Observe the mounting clearances! The contact area must be metallic bright.

3. Mount the other components, such as the mains filter, mains choke etc., on the backing plate.

The cable between mains filter and servo drive may be maximum 30 cm long.

4. Continue with the electrical installation in section 3.

Table 2.1 Mechanical installation

NOTE: For all sizes of the MSD Servo Drive Compact forced cooling by external air flow is necessary. The air must be able to flow unhindered through the device. If a temperature cut-out occurs, the cooling conditions must be improved. Air flow: minimum 1.2 m/s


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

Dimensions

MSD Servo Drive Compact C2 C3 C4

G394-030 G394-020

G394-059 G394-035

G394-080 G394-065

Weight [kg] 1.0 1.5 2.8

B (width) 55

H (height) 1) 210 290

T (depth) 1) 142 189 235.5

A 27.5

A1 - - 40

C 225 305

C1 5

D Ø 4.8

E for direct butt mounting (see note)

F 2) ≥100 ≥150

G 2) ≥235 ≥280

H1 235 315

Screws 2 x M4 4 x M4All dimensions in mm1) without terminals/connections2) The bend radius of the connecting cables must be taken into account

Table 2.2 MSD Servo Drive Compact dimensions - see Fig. 2.1 and Fig. 2.2

NOTE: The minimum distance specified in the table for sizes 2-4 applies for devices of the same power. When butt mounting devices with different drive power you should arrange the devices according to their power (e.g., viewed from the left, C4 - C3 - C2). This minimizes the thermal influence among each other.

When butt mounting MSD Servo Drive Compact drivess together with other devices, you must make sure that these device do not affect one another thermally.

C

C

C1A

B

C1

H1

H1

AB

A1

T

H

D

D

C 2 + C 3

C 2 + C 3 + C 4C 4

Fig. 2.1 Dimensions (in mm) C2, C3, C4

E

GF

F

Fig. 2.2 Mounting clearances (in mm)


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3 Installation

3.1 Notes for installationATTENTION!

•Qualified personnel Installation must only be carried out by electrical engineering experts who have been specially instructed in the necessary accident prevention measures.

•During installation work Strictly avoid that ...− screws, cable rests or foreign bodies drop into the device− moisture enters into the device

DANGER CAUSED BY HIGH VOlTAGE!

•Danger to life!− Never wire or disconnect electrical connections while they are live.

Isolate the device from the mains supply (230/400/460/480 V AC) before working on it. Even 10 minutes after switching off the mains supply dangerously high voltages of ≥50 V may still be present (capacitor charge). Work on the device must only be carried out, after the DC link voltage has dropped below a residual voltage of 50 V (indicated by monitoring lED H1 and to be measured on terminals X1/l- and l+).

− Dangerous voltage may be applied to the device, even if the device does not emit any visual or audible signals/indications (e.g. with mains voltage applied to terminal X3) and missing control supply (+24 V on X2)!

The following general guidelines apply for the installation of servo drives:

•Compliance with the EMC product standard Commissioning (i.e. starting intended operation) is only permitted when strictly complying with EMC product standard EN 61800-3. The installer/operator of a

!

machine and/or equipment must provide evidence of the compliance with the protection targets stipulated in the EMC-standard.

•Cabel type Use only shielded mains, motor and signal lines with double copper braiding that is overlapping by 60 to 70 %.

•Routing of cables

− Route mains, motor and signal cables separated from one another. If possible, keep a distance of at least 0.2 m, otherwise use separators. They should not run in parallel. If crossovers are unavoidable, they should wherever possible be configured perpendicular (at a 90° angle).

− Always route the motor cable without interruptions and the shortest way out of the control cabinet. When using a motor contactor for example, the component should be directly mounted to the drive and the shielding of the motor cable should not be stripped off too soon.

− If possible enter signal lines only from one side into the control cabinet.− lines of the same electric circuit must be twisted.− Avoid unnecessary cable lengths and loops.

•Grounding measures Grounding measures of relevance for the drive are described in section 3.5 "Connection PE conductor".

•Shielding measures Do not strip the cable shields too soon, and lay them across wide areas both on the component and on the backing plate or on the PE rail (main ground) of the backing plate.

•External components

− Place larger consumers near the supply.− Contactors, relays, solenoid valves (switched inductivities) must be wired with

fuses. The wiring must be directly connected to the respective coil.− Any switched inductance should be at least 0.2 m away from the process

controlled assemblies.

Additional information can be found in the corresponding connection description. If you require further detailed information on installation you should consult the Moog Helpline (see page 44).


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3.2 layoutThe following shows the layout with the corresponding positions of plugs and terminals. For better orientation we have identified the designations of plugs and terminals with an abbreviation.

Fig. 3.1 Layout MSD Servo Drive Compact

H1

X8

X1

X7

X6

D1, D2

T1, T2

X9

X2

X5

X13

X3

X4

Name plate Software

PE

Name plate Hardware

OP1

Number Designation

D1, D2 7-segment display

H1 DC link voltage indicator lED

OP1 Installation space for option 1 (Communication)

PE Connection PE conductor

T1, T2 Button

X1 Power connection

X2 Connection control supply UV

X3 Connection AC power supply

X4 Terminals

X5 Motor temperature monitoring

X6 Connection resolver

X7 Connection high-resolution encoder

X8 Option 2 (Technology)

X9 Ethernet interface

X13 Connection Motor brake

Table 3.1 Key to layout MSD Servo Drive Compact


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3.3 Connection diagram

Ethernet

ISD00ISD01ISD02

OSD02

Relay

ENPO (STO)

Motor3

Option 2

Control

Service interface

ISDSH (STO)

ISA00+ISA00-ISA01+

ISA01-

Analog setpoint 1

Analog setpoint 2

+24 V DC against I/O-GND

+24 V (UH)

3 4 5

6

10

151617

9

23

24

22

RSHDiagnosisSTO

12

11

1

2,14

13

I/O-GND

Relay

Digital2

RB

L+

L-

Braking resistor

UVW

6

n

n

ISD03

ISD04ISD05

18

1920

ISD0621

OSD01 8Digital1OSD00 7Digital0

GND

GNDV+

OSD03 2

34

1

59

109

DC link

OSD04

54

32

1

109

87

6

1514

1312

11

DGND

DGND

43

21

98

76

~

1+1-

1+1-

+

-

(-)(+)

D1, D2T1, T2

L1K1

L2L3

FNL1

L2

L3

3-phase systemX3

X2

X9

X4

X8

X7

X6

X5

X13

X1

Front

Option 1

+24 V DC supply for control electronics (UV)Communication

Fieldbuses

Brake (+)

+24 V DC supply for brake

Brake (-)

Resolver

-+

Encoder

+–

TOP

BOTTOM

Fig. 3.2 Connection diagram

Number Designation Details

D1, D2 7-segment display page 39

T1, T2 Button page 39

X1 Connection for motor, braking resistor and measurement of DC link voltage page 30

X2 Connection control supply page 21

X3 Connection AC power supply page 21

X4 Terminals page 24

X5 Connection motor temperature monitoring 1) page 30

X6 Connection resolver 1) page 28

X7 Connection high-resolution encoder 1) page 29

Option 1 Communication page 26

PE Connection PE conductor page 19

X8 (Option 2) Technology page 26

X9 Ethernet interface page 26

X13 Connection motor brake page 30

1) NOTE: The temperature sensor of the motor winding can be optionally connected via the encoder cables (X6 or X7) or to terminal X5.

Table 3.2 Key to connection diagram


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3.4 Effective EMC installation

3.4.1 Interference immunity of drivesATTENTION! This is a restricted availability product in accordance with IEC 61800-3. This product may cause radio interference in domestic environments; in such cases the operator may need to take appropriate countermeasures.

External radio frequency interference suppression filters (CB09937-001 to CB09940-001, CB09942-001) are available for the drives. With the measurement method specified and the external mains filter, these servo drives conform to the EMC product standard IEC 61800-3 for "First environment" (residential C2) and "Second environment" (industrial C3).

3.4.2 Specimen setupThe specimen setup presented on the following pages is intended to illustrate the key measures necessary to ensure EMC-compatible setup.

NOTE: The specimen setup merely presents a recommendation, and does not automatically guarantee compliance with applicable EMC directives. The installer/ operator of a machine and/or item of plant must provide proof of compliance with the protection targets stipulated in the standard.

Overview

Fig. 3.3 presents an overview of the minimum components required:

A. Backing plate with cable ducts

B. MSD Servo Drive Compact

C. Mains filter

D. Mains choke

E. Distributor rail for AC power supply an control supply (+24 V DC)

The layout and cabling are based on the instruction set out in section 3.1 "Notes for installation" on page 13. The numbered red arrows refer to four very important detailed notices presented on the following pages.

!

Fig. 3.3 Specimen setup - Overview

2

3

4

1

A

B

D

E

C


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

Detail 1: Motor cable

At the motor connection (X1) of the MSD Servo Drive Compact note the following points:

• Secure one of the two supplied shield connection plates by the screw to the mount on the top of the unit. Ensure the plate contacts across a wide area with the heat sink of the MSD Servo Drive Compact and with the backing plate. Use a toothed ring.

• Strip back the shield of the motor cable on the motor connection (X1) of the MSD Servo Drive Compact as little as absolutely necessary.

•Connect the motor cable shield across a wide area to the shield connection plate by the clamp supplied.

NOTE: Ready made-up motor cables are available for Moog servo motors. For details refer to the Servo motors Ordering Catalog.

Fig. 3.4 Specimen setup - Detail 1: Motor cable

X1

Detail 2: Control supply (+24 V DC)

At the control supply connection (X2):

• Secure the second of the two supplied shield connection plates by the screw to the mount on the bottom of the unit. Ensure the plate contacts across a wide area with the heat sink of the MSD Servo Drive Compact and with the backing plate. Use a toothed ring.

• Slot a shield tube over the control supply cable and strip it back only as short as necessary before the control supply connection (X2).

•Connect the shielding tube of the control supply cable across a wide area to the shield connection plate by the clamp supplied.

Fig. 3.5 Specimen setup - Detail 2: Control supply

X2


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

Detail 3: Mains filter and mains connection

At the output of the mains filter and the AC mains connection (X3):

•Connect the wire strands at the output of the mains filter directly to the AC mains (X3) of the MSD Servo Drive Compact. The strands must not be extended, so the mains filter should be installed correspondingly close to the MSD Servo Drive Compact. But be sure to maintain the necessary minimum clearance (see table 2.2 on page 12).

• Fix the strands to the shield connection plate using a cable tie as necessary.

• The leakage current of the MSD Servo Drive Compact is >3.5 mA. So:

− Connect the protective conductor from the output of the mains filter to the connection (X3) of the MSD Servo Drive Compact and

− one of the PE – connections on the heat sink of the MSD Servo Drive Compact via a cable of at least the same cross-section to the main ground of the distributor rail.

Fig. 3.6 Specimen setup - Detail 3: Mains filter and mains connection

X3

Detail 4: Control cables

At the control terminals (X4) of the MSD Servo Drive Compact:

• Strip the shielding of the control cables back only as short as absolutely necessary.

•Connect the control cable shields across a wide area to the shield connection tab of the mains filter by the clamp supplied. If this is not possible, lay the control cable shielding directly across a wide area on the backing plate directly adjacent to the MSD Servo Drive Compact.

Fig. 3.7 Specimen setup - Detail 4: Control cables

X4


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3.5 Connection PE conductor

Step ActionPE mains connection to DIN EN 61800-5-1

1.Ground each of the drives!

Connect terminal in star configuration and amply dimensioned with the PE bar (main ground) in the control cabinet.

Rules for the PE terminal (as leakage current > 3.5 mA):

Use protective conductors with the same cross-section as the mains power cables, though at least 10 mm².

Also comply with local and national regulations and conditions.

2.Also connect the PE-conductor terminals of all other components, such as mains choke, filter, etc. in a star configuration and amply dimensioned with the PE bar (main ground) in the control cabinet.

W 1V 2 W 2U 2U 1 V 1W 1V 2 W 2U 2U 1 V 1W 1V 2 W 2U 2U 1 V 1

PE

Fig. 3.8 Star configuration layout for the PE conductor


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Id no.: CA97555-001, Rev. 3.0 - Date: 06/2012

3.6 Electrical isolation conceptThe control electronics, with its logic (µP), the encoder terminals and the inputs and outputs, are electrically isolated from the power section (power supply/DC link). All control terminals are designed as safety extra-low voltage/protective extra-low voltage (SElV/PElV) circuits and must only be operated with such SElV/PElV voltages, as per the relevant specification. This provides reliable protection against electric shock on the control side.

A separate control supply, compliant with the requirements of a SElV/PElV, is therefore needed.

The opposite overview shows the potential supplies for the individual terminals in detail.

This concept also delivers higher operational safety and reliability of the drive.

SELV = Safety Extra Low Voltage PELV = Protective Extra Low Voltage

PE GNDµP DGND complexenot linearimpedance

RC link Polyswitch

GNDµP

GNDµP

GNDµP

X4/15ISD00ISD01

ILIM

X4/21ISD06

ILIM

X4/10ENPO

ILIM

X4/22ISDSH

ILIM

X4/7OSD00

X4/3ISA00+

Motor PTC

X4/4ISA00-

ISD02ISD03ISD04ISD05

A/D

A/D

ISA01+X4/5

X4/6ISA01-

X4/14

GNDµP

GNDµP

GNDµP

GNDµP

GNDµP

DGND

DGND

DGND

DGND

DGND

DGND

DGND

DGND

X4/2ϑ

F1

ϑ

F2

X4/13

DGND X4/1

ϑ

F3

VµP

VµP

VµP

VµP

µP

X4/8OSD01

OSD03Motor brake

GND

X4/9OSD02

X5/ϑ+

X5/ϑ−

RSH

X13/2

X13/1

X4/12

X4/11

OSD04

X4/23

X4/24

EthernetX9

ResolverX6

EncoderX7

PE

UV

UV

X2/+

X2/-

UH

24 V DC control supply

24 V DC Supply brake

GNDX13/3

X13/4

Fig. 3.9 Electrical isolation concept MSD Servo Drive Compact


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3.7 Connection of supply voltageThe voltage supply to the MSD Servo Drive Compact is separate for the control and power sections. The control supply should always be connected first, so that the device can be parameterized with Moog DriveADministrAtor 5 and, above all, set to the correct power supply.

ATTENTION! Only when the mains voltage has been set and the MSD Servo Drive Compact restarted (if the mains voltage or switching frequency has been changed) may the mains power supply be activated. Otherwise the device may be destroyed!

3.7.1 Connection of control supply (+24 V DC)

24 V DC ±10 %Ext. voltage source

Next servo drive

max. 10 A gG

Device 1 (e.g. C2)

+ +

Bottom

Device 2 (e.g. C2)

+

Bottom

X2

X3L1L2L3

X2

X3L1L2L3

Fig. 3.10 Connection of control supply MSD Servo Drive Compact

Control supply (Specification)

Control supply

X2/+X2/-

• UV = +24 V DC ±10%, stabilized and filtered.

• IV = 2 A (C2 to C4)

• Internal polarity reversal protection

• The power supply unit used must have a safe and reliable isolation against the mains system acc. to EN 50178 or EN 61800-5-1

Table 3.3 Specification of control supply MSD Servo Drive Compact

!

ATTENTION! Suitable measures must generally be applied to provide adequate line protection.

DANGER FROM ElECTRICAl TENSION! When the mains voltage is switched on at terminal X3 and there is no control supply (+24 V DC at X2), dangerous voltage is connected to the device with no visual signal on the display or acoustic indication by fan noise. If visible in the installed state, lED H1 (see Fig. 3.1) indicates whether voltage is connected to the device. Even when H1 is out, X1 must be checked to ensure no voltage is connected.

NOTE: The start-up current for the supply voltage to the C2 to C4 may be two to three times the operating current.

3.7.2 Connection of mains supply C2 and C3NOTE: Before commissioning, the value of the connected mains voltage must be set on the drive (factory setting = 3 x 230 V AC / 3 x 400 V AC).

C2 and C3

+X2

X3L1L2L3

L1L2L3

Mainsfilter

Mainschoke

3-phasesystem K1F1

Fig. 3.11 Connection C2 and C3 mains supply 3 x 230 V (G394-030. -059) or 3 x 400 V (G394-020, -035) depending on device design

!


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C2 and C3

+X2

X3L1L2L3

L1N

Mainsfilter

Mainschoke

1-phasesystem K1F1

Fig. 3.12 Conection C2 and C3 mains supply 1 x 230 V

3.7.3 Connection of mains supply C4NOTE: Before commissioning, the value of the connected mains voltage must be set on the drive (factory setting = 3 x 230 V AC / 3 x 400 V AC).

C4

+X2

X3L1L2L3

L1L2L3

Mainsfilter

Mainschoke

3-phasesystem

K1F1

Fig. 3.13 Connection C4 mains supply 3 x 230 V (G394-080) or 3 x 400 V (G394-065) depending on device design

C4

+X2

X3L1L2L3

L1N

Mainsfilter

Mains choke

1-phasesystem

K1F1

Fig. 3.14 Connection C4 mains supply 1 x 230 V

Procedure:

Step Action Comment

1. Specify the cable cross-section dependent on the maximum current and ambient temperature.

Cable cross-section according to local regulations and conditions.

2. Wire the drive with the mains filter*), maximum cable length 0.3 m (with non-shielded cable)!

3. Wire the mains choke*)

(if installed)

Reduces the voltage distortions (THD) in the system and prolongs the life of the drive.

4. Install a K1 circuit breaker (power circuit breaker, contactor, etc.). Do not switch on the power!

5. Use mains fuses (duty class gG) to isolate all poles of the drive from the mains supply.

For compliance with equipment safety requirements laid down in EN 61800-5-1

*) optional


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DANGER FROM ElECTRICAl TENSION! Danger to life! Never wire or disconnect electrical connections while these are live. Always disconnect the power before working on the device. Dangerously high voltages of ≥50 V may still be present 10 minutes after the power is cut (capacitor charging). So always check that the power has been cut.

ATTENTION! If local regulations require the installation of a residual current operated protective device, the following applies: In case of a fault the drive is able to generate d.c. leak currents without zero crossing. Drives therefore must only be operated with (RCDs) 1) type B for a.c. fault currents, pulsating or smooth d.c. fault currents, which are suitable for servo drive operation, see IEC 60755. RCMs 2) can additionally be used for monitoring purposes.

1) Residual current protective device 2) Residual current monitor

Note the following points:

• Switching the mains power:

− In case of too frequent switching the unit protects itself by high-resistance isolation from the system. After a rest phase of a few minutes the device is ready to start once again.

• TN and TT network: Operation is permitted if:

− in the case of single-phase devices for 1 x 230 V AC the supply system conforms to the maximum overvoltage category III as per EN 61800-5-1.

− in the case of three-phase devices with external conductor voltages 3 x 230 V AC, 3 x 400 V AC, 3 x 460 V AC and 3 x 480 V AC

1. the neutral point of the the supply system is grounded and2. the supply system conforms to the maximum overvoltage category III

as per EN 61800-5-1 at a system voltage (external conductor → neutral point) of maximum 277 V.

• IT network: not permitted!

− In case of an ground fault the electrical stress is approx. twice as high. Clearances and creepages to EN 61800-5-1 are no longer maintained.

!

•Connection of the servo drives by way of a mains choke is mandatory:

− where the drive is used in applications with disturbance variables corresponding to environment class 3, as per EN 61000-2-4 and above (hostile industrial environment)

− in the case of single-phase mains supply

− for compliance with EN 61800-3 or IEC 61800-3

• For further information on permissible current loads, technical data and ambient conditions please refer to the appendix.

NOTE: Please be aware that the MSD Servo Drive Compact is not rated for environment class 3. Further measures are essential in order for that environment class to be attained! For further information please consult your project engineer.

Drive

Device connected load 1) [kVA] Maximum

cable cross-section [mm²]

Specified mains fuse, duty class [A]with mains

choke (4% uK)without

mains choke

G394-030 1.3 1.62.5

1 x maximum 16 (1-phase) 3 x maximum 16 (3-phase)

G394-020 1.5 1.9 3 x maximum 6

G394-059 2.6 3.22.5


G394-035 2.7 3.3 3 x maximum 10

G394-080 3.5 4.34


G394-065 5.0 6.1 3 x maximum 16

1) At 3 x 230 V AC or 3 x 400 V AC mains voltage2) The minimum cross-section of the mains power cable depends on the local regulations and conditions, as well as on the

rated current of the drive.

Table 3.4 Connected load and mains fuse


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3.8 Control connections

Step Action Comment

1. Check whether a complete device setup is already available, i.e. whether the drive has already been configured.

2. If this is the case, a special control terminal assignment applies.

Please contact your project engineer to obtain the connecting assignment!

3. Choose a connecting assignment. Initial commissioning

4.Wire the control terminals with shielded cables.

The following is strictly required: STO request X4/22, ENPO X4/10 and a start signal (with control via terminal).

Ground the cable shields over a wide area at both ends.

Conductor sizes fixed: 0.2 to 1.5 mm²

Flexible conductor sizes:

- Ferrule without plastic sleeve: 0.2 to 1.5 mm²

- Ferrule with plastic sleeve: 0.2 to 0.75 mm²

5. Keep all contacts open (inputs inactive).

6. Check all connections again! Continue with commissioning in section 4.

Note the following points:•Always wire the control terminals with shielded cables.• lay the control cables separately from the mains power and motor cables.•A cable type with double copper braiding, with 60 - 70% coverage, must be used

for all shielded connections.

3.8.1 Specification of control connectionsDes. Term. Specification El. isolation

Analog inputs

REL

REL

ISDSH

ISD06

ISD05

ISD04

ISD03

ISD02

ISD01

ISD00

+24V

DGND

RSH

RSH

ENPO

OSD02

OSD01

OSD00

ISA1-

ISA1+

ISA0-

ISA0+

+24V

DGND

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

X4

ISA0+ISA0-ISA1+ISA1-

X4/3X4/4X4/5X4/6

• UIN = ±10 V DC

• Resolution 12 Bit; RIN approx. 101 kΩ

• Terminal scan cycle in "IP mode" = 125 µs, otherwise = 1 ms

• Tolerance: U ±1% of the measuring range end value

no

Digital inputs

ISD00ISD01ISD02ISD03ISD04

X4/15X4/16X4/17X4/18X4/19

• Frequency range <500 Hz

• Terminal scan cycle in = 1 ms

• Switching level low/High: ≤4.8 V / ≥18 V

• UIN max = +24 V DC +20%

• IIN at +24 V DC = typ. 3 mA

yes

ISD05ISD06

X4/20X4/21

• Frequency range ≤500 kHz


• UIN max = +24 V DC +20%

• IIN max at +24 V DC = 10 mA, RIN approx. 3 kΩ

• internal signal delay time < 2 μs suitable as trigger input for quick saving of actual position

yes

ENPO X4/10

• Disable restart inhibit (STO) and enable power stage = High level

• OSSD-capable

• Reaction time approx. 10 ms


• UIN max = +24 V DC +20%


yes

Digital outputs

OSD00OSD01OSD02

X4/7X4/8X4/9

• No destruction in case of short-circuit (+24 V DC -> DGND), but device may briefly shut down.

• Imax = 50 mA, PlC-compatible

• Terminal scan cycle in = 1 ms

• High-side driver

yes

Table 3.5 Specification of control connections X4


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Des. Term. Specification El. isolation

STO "Safe Torque Off"

REL

REL

ISDSH

ISD06

ISD05

ISD04

ISD03

ISD02

ISD01

ISD00

+24V

DGND

RSH

RSH

ENPO

OSD02

OSD01

OSD00

ISA1-

ISA1+

ISA0-

ISA0+

+24V

DGND

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

X4

ISDSH (STO) X4/22

• "Request STO" input = low level

• OSSD-capable


• UIN max = +24 V DC +20%


yes

RSHRSH

X4/11X4/12

Diagnostics STO, both tripping channels active, one NO contact with automatically resetting circuit-breaker (polyswitch) • 25 V / 200 mA AC, cos ϕ = 1

• 30 V / 200 mA DC, cos ϕ = 1

X4/12

X4/11yes

Relay outputs

RElX4/23X4/24

Relay, 1 NO contact• 25 V / 1.0 A AC, cos ϕ = 1 (AC1)

• 30 V / 1.0 A DC, cos ϕ = 1 (DC1)

• Switching delay approx. 10 ms

• Cycle time 1 ms

X4/23

X4/24

Auxilliary voltage

+24 VX4/2X4/14

• Auxiliary voltage output (UH) to feed the digital control inputs

• UH = UV-∆U (∆U typically approx. 1.2 V),no destruction in case of short circuit (+24 V DC -> DGND), but device may briefly shut down.

• Imax = 80 mA (per pin) with self-resetting circuit breaker (polyswitch)

yes

Digital ground

DGNDX4/1X4/13

Reference ground for +24 V DC yes

Table 3.5 Specification of control connections X4

3.8.2 Connection of motor brake X13Connector X13 (C2 to C4) is intended for connection of a motor brake.

Des. Term. Connection Specification

OSD03GND

GNDV+

X13/2X13/1

X13/3X13/4

Motor3

GND

OSD03

1

2

~

X13

Front

Brake (+)

Brake (-)

V+

GND3

4

24 V DC supply for brake

• Short-circuit proof

• External control supply +24 V DC (IIN = 2.1 A) required via X13/3 (GND) and X13/4 (V+)

• UBR = UV-∆U` (∆U` typically approx. 1.4 V)

• To actuate a motor holding brake up to IBR = 2.0 A maximum (for brakes with higher current requirements a relay must be interposed).

• Overcurrent causes cyclic shutdown

• Also usable as configurable digital output

• Interruptible cable break monitor < 200 mA typically in condition "1"

Table 3.6 Specification of the terminal connections X13


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3.9 Specification of Ethernet interfaceThe service and diagnostic interface X9 is executed as a TCP/IP Ethernet port. It is suitable for connection of a PC for commissioning, service and diagnostics and for programming of the drive.

The following software can communicate via the Ethernet port with the drive:

• lTi DRiVES Moog DriveADministrAtor 5 for commissioning, service and diagnostics of the MSD Servo Drive Compacts

•CoDeSys 3.x programming system for programming of the MSD Servo Drive Compact in the languages of IEC 61131-3. This requires a drive licence.

Specification of interface:

• Transfer rate 10/100 MBits/s BASE

• line protocol IEEE802.3 compliant

•Connection via standard commercially available crosslink cable, CAT 5 (e.g. Moog GnmbH accessory CC-ECl03, see also MSD Servo Drive Ordering Catalog)

3.10 Option 1Depending on the MSD Servo Drive variant, Option 1 is factory-configured with various options. Fieldbus options such as EtherCAT or Sercos are available.

You will find all available options in the MSD Servo Drive Ordering Catalog. The user manuals for the respective options provide detailed information on commissioning.

3.11 Option 2Option 2 can be fault-configured with various technology options. Additional or special encoders can be evaluated with it for example.

You will find all available options in the MSD Servo Drive Ordering Catalog. The user manuals for the respective options provide detailed information on commissioning.


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3.12 Encoder connectionAll encoder connections are located on the top of the unit.

3.12.1 Encoder connection of the synchronous motorsPlease use the ready made-up motor and encoder cables from Moog GmbH to connect the synchronous motors (see Servo motors Ordering Catalog).

3.12.2 Matching motor - encoder cable - drive connectionCompare the rating plates of the components. Make absolutely sure to use the correct components according to variant A, B or C!

Resolver

High-resolution encoder

Variant A

Variant B

Variant C

High-resolution encoderX1X6

X7 (optional X8)

Fig. 3.15 Matching motor/encoder cable

Motor (with installed encoder) Encoder cableConnection

of the servo drive

Variant Awith resolver

without further optionC08335-011-yyy X6

Variant B Sin/Cos single-turn / multi-turn encoder with SSI/EnDat interface CA58876-002-yyy X7

Variant C Sin/Cos single-turn / multi-turn encoder with HIPERFACE® interface CA58877-002-yyy X7

Table 3.7 Variants of motors, encoder type and encoder cable

NOTE: Do not split the encoder cable, for example to route the signals via terminals in the switch cabinet. The knurled screws on the D-Sub connector housing must be tightly locked!


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3.12.3 Ready made-up encoder cablesThe specifications can only be assured when using the Moog system cables.

CO8335 - 011 - yyyEncoder cable

Ready made-up cable

Resolver cable Encoder cable SSI, EnDat CA58876 Encoder cable Hiperface® CA58877

002 002

Encoder system

Version

Cable length (m)

1) yyy stands for length in meters; standard length: 1 m, 5 m, 10 m, 15 m, 20 m, 50 m. Further length on request

Encoder cable CO8335-011-yyy1) Order code

Technical data encoder cable

Technical data CO8335-011-yyy 1) CA58876-002-yyy 1) CA58877-002-yyy 1)

Motors with encoder system Resolver

(single-turn / multi-turn encoder with

SSI/EnDat interface with Sin/Cos signals)

(single-turn / multi-turn encoder with

HIPERFACE® interface with Sin/Cos signals)

Controller-end assignment (sub-D connector)

1 = S2 2 = S4 3 = S1 4 = n.c. 5 = PTC+ 6 = R1 7 = R2 8 = S3 9 = PTC-

1 = A- 2 = A+ 3 = VCC (+5 V) 4 = DATA+ 5 = DATA- 6 = B- 8 = GND 11 = B+ 12 = VCC (Sense) 13 = GND (Sense) 14 = ClK+ 15 = ClK- 7, 9, 10 = n.c.

1 = REFCOS 2 = +COS 3 = Us 7 - 12 V 4 = Data+ EIA485 5 = Data- EIA485 6 = REFSIN 7 = Jumper to PIN 12 8 = GND 11 = +SIN 12 = Jumper to PIN 7 9, 10, 13, 14, 15 = n.c.

Festoon-compatible yes

Minimum bend radius 90 mm 100 mm 90 mm

Table 3.8 Technical data encoder cable

Technical data CO8335-011-yyy 1) CA58876-002-yyy 1) CA58877-002-yyy 1)

Temperature range -40 ... +85 °C (-40 ... +185 °F)

-35 ... +80 °C (-31 ... +176 °F)

-40 ... +85 °C (-40 ... +185 °F)

Cable diameter approx. 8.8 mm

Material of outer sheath PUR

Resistance Resistant to oil, hydrolysis and microbic attack (VDE0472)

Approvals Ul-Style 20233, +80 °C (+176 °F) - 300 V, CSA-C22.2N.210-M90, +75 °C (+167 °F) - 300 V FT1

Table 3.8 Technical data encoder cable

3.12.4 Resolver connection X6A resolver is connected to slot X6 (9-pin D-Sub socket).

Fig. X6/Pin Function

54

32

1

98

76

X6

Resolver

1 Sin+ / (S2) analog differential input track A

2 Refsin / (S4) analog differential input track A

3 Cos+ / (S1) analog differential input track B

4 Supply voltage 5 ... 12 V, internally connected to X7/3

5 ϑ+ (PTC, KTY, Klixon) internally connected to X7/10 1)

6 Ref+ analog excitation

7 Ref- analog excitation (ground reference point to pin 6 and pin 4)

8 Refcos / (S3) analog differential input B

9 ϑ- (PTC, KTY, Klixon) internally connected to X7/9 1)

1) Be sure to pay attention to the notice headed "ATTENTION" in Table 3.12!

Table 3.9 Pin assignment X6 resolver connection


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3.12.5 Connection for high-resolution encoderThe interface X7 enables evaluation of the following encoder types.

Fig. Function

54

32

1

109

87

6

1514

1312

11

X7

Enco

der

/ SS

I

Sin/Cos encoder with zero pulsee.g. Heidenhain ERN1381, ROD486

Heidenhain Sin/Cos encoder with EnDat interfacee.g. 13 bit single-turn encoder(ECN1313.EnDat01) and 25 bit multi-turn encoder (EQN1325-EnDat01)

Heidenhain encoder with digital EnDat interfaceSingle or multi-turn encoder

Sin/Cos encoder with SSI interfacee.g. 13 bit single-turn and 25 bit multi-turn encoder (ECN413-SSI, EQN425-SSI)

Sick-Stegmann Sin/Cos encoder with HIPERFACE® interfaceSingle and multi-turn encoder, e.g. SRS50, SRM50

Table 3.10 Suitable encoder types on X7

NOTES:• The usage of encoders not included in the range supplied by Moog GmbH

requires special approval by Moog GmbH.

• The maximum signal input frequency is 500 kHz.

• Encoders with a power supply of 5 V ± 5 % must have a separate sensor cable connection. The encoder cable detects the actual supply voltage at the encoder, thereby compensating for the voltage drop on the cable. Only use of the sensor cable ensures that the encoder is supplied with the correct voltage. The sensor cable must always be connected.

Select the cable type specified by the motor or encoder manufacturer, bearing in mind the following:

•Always used shielded cables. Apply the shield on both sides.

•Connect the differential track signals A, B, R or ClK, DATA to each other via twisted wires.

•Do not separate the encoder cable, for example to route the signals via terminals in the switch cabinet.

Fig.X7 Pin

Sin/Cos and TTL

Sin/Cos Absolute encoder

SSI/EnDat

Absolute encoder EnDat

(digital)

Absolute encoder

HIPER-FACE®

54

32

1

109

87

6

1514

1312

11

X7

Enco

der

/ SS

I

1 A- A- - REFCOS

2 A+ A+ - +COS

3+5 V DC ±5%, IOUT max = 250 mA

(150 mA for hardware versions 0..1), moni-toring via sensor cable

7 to 12 V (typ. 11 V) maximum 100 mA

The sum of the currents tapped at X7/3 and X6/4 must not exceed the specified value!

4 R+ Data + Data + Data +

5 R- Data - Data - Data -

6 B- B- - REFSIN

7 - - - US - Switch

8 GND GND GND GND

9 ϑ- (PTC , KTY, Klixon) internally connected to X6/9 1)

10 ϑ+ (PTC , KTY, Klixon) internally connected to X6/5 1)

11 B+ B+ - +SIN

12 Sense + Sense + Sense + US - Switch

13 Sense - Sense - Sense - - After connecting pin 7 to pin 12, a voltage of 11.8 V is set at X7/3 and X6/4!

14 - ClK+ ClK+ -

15 - ClK - ClK - -

1) Be sure to pay attention to the notice headed "ATTENTION" in table 3.12!

Table 3.11 Pin assignment of the X7 terminal connection

NOTE: The encoder supply at X7/3 is short-circuit proof in both 5 V and 11 V operation. The drive remains in operation enabling the generation of a corresponding error message when evaluating the encoder signals.


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3.13 Motor connection

Step Action Comment

1. Specify the cable cross-section dependent on the maximum current and ambient temperature.

Cable cross-section according to local and country-specific regulations and conditions.

2. Connect the shielded motor cable to terminals X1/ U, V, W and connect the motor to ground at .

Mount shield at both ends to reduce interference emission.

3. Wire the motor temperature sensor and activate temperature evaluation by means of Moog DriveADministrAtor. See also related note.

Mount shield at both ends to reduce interference emission.

Motor temperature sensor

ATTENTION! The motor PTC when connected to X5 must be provided with basic insulation, against the motor winding and when connected to X6 or X7 must be provided with reinforced insulation as per EN 61800-5-1.

X5 Temperature switch (Klixon), PTC Sensor with basic insulation

X6 Temperature switch (Klixon), PTC, KTY Sensor with increased insulation

X7 Temperature switch (Klixon), PTC, KTY Sensor with increased insulation

Table 3.12 Motor temperature sensor terminal configuration

NOTE: In the event of a short-circuit or ground fault in the motor cable, the power stage is disabled and an error message is issued.

!

3.13.1 Connection of the servo motorsPlease use a ready made-up motor cable to connect servo motors.

Motor3

Option 2

RB

L+

L-

Brakingresistor

UVW

6

n

n

59

109

DC link

~

1+1-

1+1-

+

-

(-)(+)

X8

X7

X6

X5

X13

X1

Front

Brake (+ )

Brake (-)

Resolver

Encoder

Top

GND

GNDV+

OSD03 2

34

1

24 V DC supplyfor brake

Fig. 3.16 Connection of motor

ATTENTION! DC linking of multiple servo drives is not permitted!

!


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3.13.2 Ready made-up motor cable

C08336 - xxx yyy1)

Ready made-up motor cable

Configuration option

Cable length (m)

1) yyy stands for length in meters; standard length: 1 m, 5 m, 10 m, 15 m, 20 m, 50 m. Further length on request

Motor cable C08336-xxx-yyy Order code

Technical data motor cable

Technical data C08336-xxx-yyy1),2) CB05708-xxx-yyy1),2)

Continous rated current 10 A TBD

Surge current 30 A (90s at +72.7 °C) (+162.9 °F) TBD

Minimum bend radiusIn fixed installation: 60 mm

In flexible use: 120 mmTBD

Cable diameter range 9 to 14.4 mm TBD

Cable cross-section 4 x 1.5 mm² + 2 x 1 mm²

4 x 4 mm² + 2 x 1.5 mm²

Temperature range -50 °C to +90 °C (-58 °F to +194 °F) TBD

Wiring

Connector pin / Wiring

2 / U 4 / VV

1 / WWW PE / yellow; green 5 / Brake +; white 6 / Brake -; black

Connector housing / Screen

Connector type Size 1

2) xxx-001 for standard configuration option, others on request

Table 3.13 Technical data motor cable (Connector type Size 1)

Technical data C08733-xxx-yyy1),2) B47916-xxx-yyy1),2) CA98676-yyy1),2)

Continous rated current 44 A 61 A 82 A

Surge current TBD

Minimum bend radiusIn fixed installation: 60 mm

In flexible use: 120 mmTBD

Cable diameter range 16.2 ±3 mm TBD

Cable cross-section 4 x 6 mm² + 2 x 1 mm²

4 x 10 mm² + 2 x 1.5 mm²

4 x 16 mm² + 2 x 1.5 mm²

Temperature range -50 °C to +90 °C (-58 °F to +194 °F) TBD

Wiring

Connector pin / Wiring

U / U V / VV

W / WWW PE / yellow; green + / Brake +; white - / Brake -; black

Connector housing / Screen

Connector type Size 1.5

2) xxx-001 for standard configuration option, others on request

Table 3.14 Technical data motor cable (Connector type Size 1.5)

NOTE: Wires 5 and 6 (PTC) are required only for motors in which the motor PTC cannot be connected via the encoder cable. In the case of synchronous motors with resolver, the PTC is connected via the resolver cable.


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3.13.3 Switching in the motor cableATTENTION! Switching in the motor cable must take place with the power cut and the power stage disabled, as otherwise problems such as burned-off contactor contacts may occur. In order to ensure unpowered switch-on, you must make sure that the contacts of the motor contactor are closed before the drive power stage is enabled. At the moment the contactor is switched off it is necessary for the contact to remain closed until the drive power stage is shut down and the motor current is 0. This is done by inserting appropriate safety times for switching of the motor contactor in the control sequence of your machine.

Despite these measures, the possibility cannot be ruled out that the drive may malfunction during switching in the motor cable.

!

3.14 Braking resistor (RB)In regenerative operation, e.g. when braking the drive, the motor feeds energy back to the drive. This increases the voltage in the DC link. If the voltage exceeds a threshold value, the internal braking transistor is activated and the regenerated power is converted into heat by means of a braking resistor.

3.14.1 Protection in case of braking chopper faultATTENTION! If the internal braking chopper transistor is permanently switched on, because it is alloyed through by overload (= 0 Ω), there is a protective function to protect the device against overheating.

You activate this function by assigning to any digital output (Moog DriveADministrAtor 5 expert field "I/O configuration" digital outputs OSD00 to OSD02) with BC_FAIL(56). In the event of a fault the selected output then switches from 24 V to 0 V. This signal ensures that the drive is safely disconnected from the mains supply.

For detailed information on parameterization refer to the MSD Servo Drive application manual.

3.14.2 Design with integrated braking resistor (C3 + C4)The Ordering Catalog only specifies the peak braking power for the servo drives with integrated braking resistor (model G394-xxx-xxx-xx2). The permissible continuous braking power must be calculated. It depends on the effective loading of the drive in the corresponding application.

The drive is thermally designed in such a way that no energy input by the internal braking resistor is permitted during continuous operation with rated current and at maximum ambient temperature.

Consequently, a drive design featuring an integrated braking resistor only makes sense when the effective drive load is ≤80% or the braking resistor is designed for one-off emergency stop. In the event of an emergency stop, only the heat capacity of the braking resistor can be used for a one-off braking action. The permissible energy WIBr can be taken from the following table.

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Device TechnologyRated

resistance RBR

Peak braking power PPBr

Pulse energy WIBr

K1

G394-059

Wire resistance

100 Ω 1500 W 1) 150 Ws 120

G394-035 420 Ω1000 W 2)

1300 W 3)

1400 W 4)

140 Ws 50

G394-080

90 Ω

1690 W 1) 6000 Ws 170

G394-0654700 W 2)

6170 W 3)

6500 W 4)

6000 Ws 120

1) Data referred to 1 x 230 V AC mains voltage (BR switch-on threshold 390 V DC)2) Data referred to 3 x 400 V AC mains voltage (BR switch-on threshold 650 V DC)3) Data referred to 3 x 460 V AC mains voltage (BR switch-on threshold 745 V DC)4) Data referred to 3 x 480 V AC mains voltage (BR switch-on threshold 765 V DC)

Table 3.15 Data of the integrated braking resistor (design G394-xxx-xxx-xx2)

If the drive is not permanently operated at its power limit, the saved power dissipation of the drive can be used as braking power.

NOTE: Further calculation assumes that the drive is used at maximum permissible ambient temperature. This means that any additional energy input from the internal braking resistor caused by low ambient temperature will be neglected.

Method to calculate the continuous braking power:

•Calculation of effective drive loading in a cycle T:

dtiT

IT

eff ∫=0

21

11 KII

PN

effDBr ×−=

Br

T

PBrDBr dtPT

P ∫×≥0

1

∫×

=T

BrDBr

PBr dtPPT

0

TPPTDBr

PBrBrSum ×=

•Determination of permissible continuous braking power based on unused drive power:

dtiT

IT

eff ∫=0

21

11 KII

PN

effDBr ×−=

Br

T

PBrDBr dtPT

P ∫×≥0

1

∫×

=T

BrDBr

PBr dtPPT

0

TPPTDBr

PBrBrSum ×=

Marginal conditions

•A single braking action must not exceed the maximum pulse energy of the braking resistor.

WIBr ≥ PPBr x TBr

• The continuous braking power calculated for the device must be greater than the ef-fective braking power of a device cycle.

dtiT

IT

eff ∫=0

21

11 KII

PN

effDBr ×−=

Br

T

PBrDBr dtPT

P ∫×≥0

1

∫×

=T

BrDBr

PBr dtPPT

0

TPPTDBr

PBrBrSum ×=

This results in the minimum permissible cycle time T with calculated continuous braking power:

dtiT

IT

eff ∫=0

21

11 KII

PN

effDBr ×−=

Br

T

PBrDBr dtPT

P ∫×≥0

1

∫×

=T

BrDBr

PBr dtPPT

0

TPPTDBr

PBrBrSum ×=

The maximum total on-time of the braking resistor over a specified cycle time T with calculated continuous braking power results as:

dtiT

IT

eff ∫=0

21

11 KII

PN

effDBr ×−=

Br

T

PBrDBr dtPT

P ∫×≥0

1

∫×

=T

BrDBr

PBr dtPPT

0

TPPTDBr

PBrBrSum ×=

ATTENTION! No additional external braking resistor may be connected to drives G394-035 - G394-080 with integrated braking resistor.!


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3.14.3 Connection of an external braking resistorATTENTION!

• Be sure to follow the installation instructions for the external braking resistor.

• The temperature sensor (bimetal switch) on the braking resistor must be wired in such a way that the power stage is deactivated and the connected drive is disconnected from the mains supply if the braking resistor overheats.

• The minimum permissible connection resistance of the drive must not be infringed – for technical data see section A.2 on page 49.

• The braking resistor must be connected by a shielded cable.

Size C2 to C4

RB

L+Brakingresistor

X1

Top

Fig. 3.17 Connection braking resistor

ATTENTION! No additional external braking resistor of the C3 and C4 (G394-035 - G394-080) must be connected to the drive with integrated braking resistor.

!

!

DANGER FROM ElECTRICAl TENSION! Danger to life! Never wire or disconnect electrical connections while these are live. Always disconnect the power before working on the device. Dangerously high voltages of ≥50 V may still be present 10 minutes after the power is cut (capacitor charging). So always check that the power has been cut!

ATTENTION! The external braking resistor must be monitored by the control. The temperature of the braking resistor is monitored by a temperature watchdog (Klixon). In the event of overheating the drive must be disconnected from the mains supply.

Available braking resistors (excerpt)

Article designation

Continuous braking power

Resist-ance1)

Peak braking power 2)

Protec-tion

Fig.

CA59737-001 35 W

90 Ω

6250 W IP54

Example: CA59737-001

CA59738-001 150 W 6250 W IP54

CA59739-001 300 W 6250 W IP54

CA59740-001 1000 W 6250 W IP65

1) Tolerance ±10%2) The maximum possible braking power dependent on ON-time and cycle time

Table 3.16 Technical data - braking resistors

NOTE: The available braking resistors with the exact specifications, in particular with regard to surface temperature, maximum system voltage and high-voltage strength, are set out in the MSD Servo Drive Ordering Catalog.

Please consult your projecting engineer for more detailed information on the design of braking resistors.

!


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4 Commissioning

4.1 Notes for operationATTENTION!

•Notes on safety During operation pay attention to the notes on safety in chapter 1

•During operation Strictly avoid that ...− foreign objects or moisture enters into the device− aggressive or conductive substances are in the vicinity− ventilation openings are covered

•Cooling− The device heats up during the operation and the temperature on the

heat may reach +100 °C (+212 °F). Danger of skin injury when touching.− Cooling air must be able to flow through the device without restriction.

!

4.2 Initial commissioningOnce the MSD Servo Drive Compact has been installed as described in chapter 2 and wired with all required voltage supplies and external components as described in chapter 3, initial commissioning can performed in the following sequence:

Step Action Comment

1. Installation and start of PC software see Installation Manual Moog DriveADministrAtor 5

2. Switching on control voltage see section 4.2.1

3. Connection between PC and drive see section 4.2.2

4. Parameter setting see section 4.2.3

5. Drive control with Moog DriveADministrAtor 5 see section 4.2.4

NOTE: Details concerning STO (Safe Torque Off) have not been taken into account for initial commissioning, see chapter 6


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4.2.1 Switching on control supply

2. First only switch on the +24 V DC control supply for initializing and param-eterizing. Do not yet switch on the AC mains supply..

Display reading after switching on the control supply

D1 D2 Action Explanation

Switching on the external +24 V DC control supply Initialization is running

Initialization completed Not ready for starting

Table 4.1 Switch-on status of the MSD Servo Drive (after connection of the +24 V DC control supply)

NOTE: Details concerning the control supply can be found in section 3.7 „Connection of supply voltage” starting at page 21.

4.2.2 Connection between PC and servo drive

3. The PC can be linked with the drive via Ethernet (TCP/IP). Connect PC and drive with an ethernet connecting cable.

NOTES:• Initialization

The communication link between PC and drive can only be set up after the drive has completed the initialization.

• TCP/IP configuration If the PC does not recognize the connected drive you should check the driver or the settings for the corresponding interfaces (see installation manual Moog DriveADministrAtor 5).

4.2.3 Parameter setting

4. The Commissioning Wizard in Moog DriveADministrAtor 5 helps to make settings to the drive system. Start the wizard.

NOTES:•Help Moog DriveADministrAtor

A detailed description of Moog DriveADministrAtor 5 as well as the commissioning wizard can be found in the Moog DriveADministrAtor 5 help system.

•Motor dataset If you intend to use a Moog Servo Motor, motor datasets are available.

4.2.4 Drive control with Moog DriveADministrAtor 5

5. Switch on the AC mains supply. Subsequently enable the power stage and activate the drive. The drive should be tested without the coupled mechan-ics.

DANGER CAUSED BY ROTATING PARTS! Danger to life from uncontrolled rotation! Before starting motors with feather keys in the shaft end these must be reliably secured against being ejected, as far as this is not already prevented by drive elements such as belt pulleys, couplings or similar.

!ATTENTION!

•Avoid damage caused by motor test run! In this case it must be assured that the test will not cause any damage to the system! Pay particular attention to the limitations of the travel range. Please note that you yourself are responsible for safe operation. Moog GmbH will not assume liability for any occurring damage.

•Destruction of motor!


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− Certain motors are intended for operation on the servo drive. Direct connection to the mains supply can destroy the motor.

− The motor surfaces may become extremely hot. No temperature sensitive parts may touch or be mounted to these areas, appropriate measures to prevent contact must be applied wherever necessary.

− In order to avoid overheating of the motor, the temperature sensor installed in the winding must be connected to the terminals of the tem-perature monitoring system for the servo drive (X5 or X6).

− The motor brake (if installed) should be checked for fault-free functioning before commissioning of the motor. Standstill holding brakes are only designed for a limited number of emergency braking operations. se as working brake is strictly prohibited.

Display reading after switching on the AC mains supply

D1 D2 Action Reaction Explanation

Switching on the AC mains supply

Control ready, power stage ready, control deactivated

Device is ready for switching on

Table 4.2 Display D1/D2 after switching on the AC mains supply

NOTES:• Inputs "ISDSH" and "ENPO"

For step 1 in table 4.3 at least the two inputs “ISDSH” and “ENPO” for terminal X4 must be interconnected.

•Manual operation dialog For step 2 in table 4.3 best via the “Manual operation” dialog of Moog DriveADministrAtor 5, details can be found in the help system.

•Configuration of inputs/outputs If step 2 is to be executed via the inputs of terminal X4, the sources for “START CONTROl” and speed setpoint must be configured accordingly in the subject area “Inputs/Outputs” of Moog DriveADministrAtor 5.

Switching on sequence to start the drive

1. Deactivate the safety function "STO" by setting the inputs ISDSH” and “ENPO” (see chapter 6).

ISDSH (STO)

ENPO (STO)

10

t

10

0

2. Activate “START CONTROl” at the earliest 2 ms after step 1 and specify the speed setpoint.

START

t0

10

≥ 2 ms

3. Monitor your system or plant and check the drive behaviour.

TECHNOLOGY ENABLED(state 5)

t

t0

10

t = motor dependent delay time

Table 4.3 Switching on sequence

Display reading after start of drive

D1 D2 Action Reaction Explanation

Enable “STO“ and power stage “ENPO“ Ready for switching on Power stage ready

ATTENTION! Before the next step “Enable start” you must specify a plausible setpoint, because the pre-set setpoint is transferred to the drive directly after the motor control has started.

“Start“ enabled Technology enabled Motor energized, control active

Table 4.4 Display D1/D2 during activation of motor

Details for optimizing the drive on your application can be found in the Moog DriveADministrAtor 5 Online help and in the MSD Servo Drive Application Manual.

!


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4.3 Serial commissioningAn existing parameter dataset can be transferred to other MSD Servo Drive Compacts by using Moog DriveADministrAtor 5. Details can be found in the Moog DriveADministrAtor 5 help system.

4.4 Integrated control unitThe built-in operator control unit permits diagnostics of the MSD Servo Drive Compact. The operator control unit comprises the following elements, all located on the front of the device:

• 2-digit 7-segment display (D1, D2)

• 2 buttons (T1, T2)

Fig. 4.1 Integrated control unit MSD Servo Drive Compact

The following functions and displays are available:

•Display of device state (see section 5.1 "Device states“ on page 43) The device state is displayed after switching on the control voltage. If no input is made via the keypad for 60 seconds, the display switches back to the device state.

•Display of device error state (see page 43) If a device error occurs the display immediately switches to show the error code.

• Parameter setting (display "PA") (see section 4.4.3) Resetting device parameters to their factory setting.

• Ethernet IP address setting (display "IP") (see section 4.4.4) Setting of the Ethernet IP address and the subnet mask.

• Fieldbus settings (display "Fb") (see section 4.4.5) Setting of fieldbus address for example.

D1 D2

T2

T1


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4.4.1 Function of buttons T1 and T2These buttons are used to activate the different menus and to control the corresponding functions.

Button Function Comment

T1 (left) • Activation of menu (exit the device status display)

• Scrolling through the menus/sub-menus

• Setting of values - left segment display (D1)

The button T1 can be held de-pressed for any time, because the display will only scroll through the menu options of the corresponding level. No settings will be changed.

T2 (right) • Selection of chosen menu

• Setting of values - right segment display (D2)

The button T2 must not be held depressed for any length of time, because the display will change from one menu level to the next within the menu structure and then change the parameter that is reached at the end. You should therefore always release the button T2 after each change in display.

T1 and T2 together

• Menu level up

• Accept selection

• Acknowledge

When pressing T1 and T2 at the same time, the accepted value will be flashing for five seconds. During this time the Save procedure can still be aborted by pressing any button, without the set value being accepted. Otherwise the new value will be saved after 5 seconds.

General • The time the button needs to be held depressed until an action is executed, is approx. 1 second.

• If there is no action by the user over a period of 60 seconds, the display returns to the device status display.

Table 4.5 Function of buttons T1 and T2

4.4.2 DisplayThe following table defines various displays and status information about the display.

Display Meaning

Menu entries

(“PA“ in this case serves as an example, further possible entries see section 4.4.4 and 4.4.5)

[flashing decimal points]

Selected function in action

[two dashes]

Entry/function not available

[OK]

Action executed successfully, no errors

[Error]• Action via control unit not executed successfully,

“Er“ flashes in alternation with error number (see section 4.4.3)

• Display device error, “Er“ flashes in alternation with error number and error location (see “MSD Servo Drive Application Manual“)

Numerical values

(“10” in this case serves as an example)• In the parameter menu (PA) error numbers are shown as deci-

mal.• All other values are displayed in hexadecimal mode. In these

cases the diplayed 10 would represent the decimal value 16

Table 4.6 Meaning of display

NOTE: If no input is made via the keyboard over a period of 60 seconds, the display returns to the device status display.


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4.4.3 Parameter menu (PA)On the Parameter menu the device settings can be reset to their factory defaults.

Menu level Param-eter

Value range

Meaning Explanation1 2

PA Pr - - Parameter reset Reset device settings to factory defaults

Table 4.7 Parameter menu

Error numbers

A failed user action is indicated by an error message. The message consists of an alternating display of "Er" and the error number.

NOTE: The error messages displayed during user input should not be confused with drive error messages. For detailed information on the error codes and on error management refer to the "MSD Servo Drive Application Manual".

Error number Meaning

17 Parameter reset to factory settings failed

18 Parameter write access failed

19 Save parameter data set non volatile failed

20 Not all parameters written

21 Error while reset to factory settings

Table 4.8 Error numbers

4.4.4 Ethernet IP-address menu (IP)An Ethernet TCP/IP port is available as a service and diagnostics interface. The IP address is set by default to 192.168.39.5 and the subnet mask to 255.255.255.0. Both can be changed by way of the IP-address menu.

Menu level Pa-ram-eter

Value range


IP Iu b0 00..FF IP address update Byte 0

Setting of byte 0 of the IP address in hexadecimal format (e.g. "05" at 192.168.39.5)

b1 00..FF IP address update Byte 1

Setting of byte 1 of the IP address in hexadecimal format (e.g. "27" at 192.168.39.5)


Setting of byte 2 of the IP address in hexadecimal format (e.g. "A8" at 192.168.39.5)


Setting of byte 3 of the IP address in hexadecimal format (e.g. "C0" at 192.168.39.5)

Ir - - IP reset to factory setting

Reset IP address to factory default (192.168.39.5)

Su b0 00..FF Subnetmask update Byte 0

Setting of byte 0 of the subnet mask in hexadecimal format (e.g. "00" at 255.255.255.0)

b1 00..FF Subnetmask update Byte 1

Setting of byte 1 of the subnet mask in hexadecimal format (e.g. "FF" at 255.255.255.0)





Sr - - Subnetmask reset to

factory setting

Reset subnet mask to factory default setting (255.255.255.0)

Table 4.9 IP-address menu


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Example configuration of subnet mask

In this example the subnet mask is changed from 255.255.255.0 to 122.255.255.0.

NOTE: Changes on the IP-address menu are only saved when the control electronics are subsequently restarted.

T1

T2

Tx

TxBack

Back

Back

Apply

>5 s>5 s

<5 s

T2

<5 s

T1 T2

T1 T2

T1 T2

Back

T1 T2

BackT1 T2

T1 T2

T1 T2

T1 T2

T1 T2

T1

T1

Back

T1 T2T2

Press button Tx (X= 1,2) repeatedly until desired menuappears on display

Value NOT saved

Value saved

Press button Tx (X= 1,2) once

Press any button

Press buttons T1 and T2 simultaneously

Fig. 4.2 Example configuration of subnet mask


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4.4.5 Fieldbus address menu (Fb)The functions available under this menu item depend on the device expansion option. For detailed information refer to the relevant specification.

Menu level Param-eter

Value range


Fb Ad - 00..xxor- -

Fieldbus address Setting of fieldbus address (only when fieldbus option used), otherwise display "- -" (The maximum programmable value depends on the option)

Po - 0..3or- -

Transmit power Setting of fibre-optic power output (only with SERCOS II option), otherwise display "- -"

Table 4.10 Fieldbus address menu

Example configuration of fieldbus address

In this example the fieldbus address is changed from 1 to 23.

NOTE: Changes on the fieldbus address menu are only saved when the control electronics are subsequently restarted.

Tx

Tx

T2

T2

T1 T2T1 T2

T1 T2

>5 s>5 s

<5 s

<5 s

T1 T2

T1 T2 T1 T2

T1 T2

T1

Back

Back

Press button Tx (X= 1,2) repeatedly until desired menuappears on display

Back

Apply

Value NOT saved

Value saved

Press button Tx (X= 1,2) once

Press any button

Press buttons T1 and T2 simultaneously

Fig. 4.3 Example configuration of fieldbus address

moog 43MSD Servo Drive Compact Operation Manual

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5 Diagnostics

The device states and error displays are indicated on the device by way of the 7-segment display of the integrated operator control unit.

5.1 Device states

Display System status

Device in reset state

Self-initialization on device startup

*) Not ready to switch on (no DC link voltage) 1)

*) Start inhibit (DC link OK, power stage not ready) 1)

Ready (power stage ready)

Switched on (drive powered) 2)

Drive ready (power applied to drive and drive ready for setpoint input) 2)

Quick stop 2)

Error response active 2)

*) Not a “safe indication” as specified in EN 61800-5-2.1) S. flashes when the STO (Safe Torque Off) function is active, display goes out when function is inactive.2) The dot flashes when the power stage is active.

Table 5.1 Device states

5.2 Error displayThe 7-segment display shows the specific error codes. Each error code comprises the alternating sequence ”Er” error number error location.

Display Meaning

Device error

↓ Display changes after approx. 1 s

Error number (decimal) Example: 05 = Overcurrent

↓ Display changes after approx. 1 s

Error location (decimal) Example: 01 = Hardware monitoring

↑ After approx. 1 s the display jumps to ER

Table 5.2 Display of the error code

NOTE: The errors can be reset in accordance with their programmed reaction (ER) or only via a +24 V DC reset (X2) (ER.). Errors marked with a dot can only be reset when the cause of the fault has been eliminated.

5.3 Error codesNOTE: For detailed information on the error codes and on error management refer to the “MSD Servo Drive Application Manual”.


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5.4 Helpline/Support & ServiceOur Helpline can provide you with fast, targeted assistance if you have any technical queries relating to project planning or commissioning of the servo drive. To that end, please collect the following information prior to making contact:

1. Type designation, serial number and software version of the devices (see software name plate)

2. Moog DriveADministrAtor version in use (menu Help Information... Version)

3. Displayed error code version (on 7-segment display or Moog DriveADministrAtor)

4. Description of the error symptoms, how it occurred and relevant circumstances

5. Save device settings to file in Moog DriveADministrAtor

6. Name of company and contact, telephone number and e-mail address

If you have any technical questions concerning project planning or commissioning of the servo drive, please feel free to contact our helpline.

•Helpline - Please contact us: Moog GmbH Hanns-Klemm-Straße 28 D-71034 Böblingen Phone: +49 7031 622 0 Telefax: +49 7031 622 100 E-Mail: [email protected]

If you need further assistance, our specialists at the Moog Service Center will be happy to help.

• Service - Please contact us: Phone: +49 7031 622 0 E-Mail: [email protected]


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6 Safe Torque Off (STO)

NOTE: You will find all information on the “STO” function in the 24-language document “Description of the STO Safety Function” (Id no. CB19388).


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A Appendix

A.1 Current capacity of servo drivesThe maximum permissible servo drive output current and the peak current are dependent on the mains voltage, the motor cable length, the power stage switching frequency and the ambient temperature. If the conditions change, the maximum permissible current capacity of the servo drives also changes.

MSD Servo Drive Compact for 1 x 230 V

Device

Switching frequency of power stage

Ambient temperature

maximum

Rated current IN [Aeff]

Peak current

200% (2 IN) 300% (3 IN)

[kHz] [°C (°F)] at 1 x 230 V [Aeff]for time

[s][Aeff]

for time [s]

G394-030

4 +45 (+113) 3.0 6.0

10

9.0 0.08

8 +40 (+104) 3.0 6.0 9.0 1) 0.08 1)

16 +40 (+104) 2.0 4.0 6.0 1) 0.08 1)

G394-059

4 +45 (+113)

5.9 11.8 10 - -8 +40 (+104)

16 +40 (+104)

G394-080

4 +45 (+113) 8.0 16.0

10 - -8 +40 (+104) 8.0 16.0

16 +40 (+104) 5.4 10.8

1) Automatic power stage switching frequency change to 4 kHz.Data applies to motor cable length ≤10m. Maximum permissible motor cable length 30 m.All current ratings with recommended mains choke.

Table A.1 Rated current and peak current C2 to C4 (1 x 230 V AC)

MSD Servo Drive Compact for 3 x 230 V

Device

Switching frequency of power stage

Ambient temperature

maximum


Peak current

200% (2 IN) 300% (3 IN)

[kHz] [°C (°F)] at 3 x 230 V [Aeff]for time

[s][Aeff]

for time [s]

G394-030

4 +45 (+113) 3.0 6.0

10

9.0

0.088 +40 (+104) 3.0 6.0 9.0 1)

16 +40 (+104) 2.0 4.0 6.0 1)

G394-059

4 +45 (+113)

5.9 11.8 10

17.7

0.088 +40 (+104) 17.7 1)

16 +40 (+104) 17.7 1)

G394-080

4 +45 (+113) 8.0 16.0

10

24.0

0.088 +40 (+104) 8.0 16.0 24.0 1)

16 +40 (+104) 5.4 10.8 16.2 1)

1) Automatic power stage switching frequency change to 4 kHz. Data applies to motor cable length ≤10m. Maximum permissible motor cable length 30 m.

Table A.2 Rated current and peak current C2 to C4 (3 x 230 V AC)


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MSD Servo Drive Compact for 3 x 400/460/480 V

Device

Switching frequency of power

stage

Ambient tempera-

ture maximum


Peak current 2)

200% (2 IN) 300% (3 IN)

[kHz] [°C (°F)]at

400 Vat

460 Vat

480 V[Aeff]

for time [s]

[Aeff]for

time [s]

G394-020

4 +45 (+113) 2.0 2.0 2.0 4.0

10

6.0

0.088 +40 (+104) 2.0 2.0 1.7 4.0 6.0 1)

16 +40 (+104) 0.7 0.7 - 1.4 2.1 1)

G394-035

4 +45 (+113) 3.5 3.5 3.5 7.0

10

10.5

0.088 +40 (+104) 3.5 3.5 2.6 7.0 10.5 1)

16 +40 (+104) 2.2 1.3 - 4.4 6.6 1)

G394-065

4 +45 (+113) 6.5 6.5 6.5 13.0

10

19.5

0.088 +40 (+104) 6.5 6.5 6.5 13.0 19.5 1)

16 +40 (+104) 4.0 2.4 1.9 8.0 12.0 1)

1) Automatic power stage switching frequency change to 4 kHz.2) Data referred to 3 x 400 V mains voltageData applies to motor cable length ≤10m. Maximum permissible motor cable length 30 m.

Table A.3 Rated current and peak current C2 to C4 (3 x 400/460/480 V AC)


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A.2 Technical data MSD Servo Drive Compact

G394-030, G394-059 and G394-080

Designation

Technical data

G394-030 G394-059 G394-080

Output motor side 1)

Voltage 3 phase UMains

Continuous current effective (ln) 2) 3 A 5.9 A 8 A

Peak current (Aeffective) see table A.1 and A.2

Rotating field frequency 0 ... 400 Hz

Switching frequency of power stage 4, 8, 16 kHz

Input mains side

Mains voltage (1 x 230 V AC / 3 x 230 V AC) -20%/+15%

Device connected load 1)

(with mains choke) 1.3 kVA 2.6 kVA 3.5 kVA

Current 1)

(with mains choke)

1 x 230 V AC 5.4 A 10.6 A 14.4 A

3 x 230 V AC 3.3 A 6.5 A 8.8 A

Asymmetry of mains voltage ±3% maximum

Frequency 50/60 Hz ±10%

Power loss at IN 1) 75 W 150 W 200 W

1) Data referred to output voltage 230 V AC and switching frequency 8 kHz.2) For rated current refer to table A.1 or table A.2!3) Connection of ext. braking resistor not permitted to devices with int. braking resistor (design G394-xxx-xxx-xx2)!4) Braking resistor always integrated. Connection of an external resistor is permissible.5) Option (G394-xxx-xxx-xx2)

Table A.4 Technical data G394-030, G394-059 and G394-080

Designation

Technical data

G394-030 G394-059 G394-080

DC link

Braking chopper switch-on treshold 390 V DC

Minimum ohmic resistance of an externally installed braking resistor

72 Ω 72 Ω 3) 72 Ω 3)

Brake chopper continuous power with external braking resistor 2.1 kW

Peak brake chopper with external braking resistor 2.1 kW

Internal braking resistor 550 Ω (PTC) 4) 100 Ω 5) 90 Ω 5)

Brake chopper continuous power with internal braking resistor 0 W depending on the effective load on the

drive in the specific application

Peak brake chopper with internal braking resistor 400 W 1500 W 1700 W

1) Data referred to output voltage 230 V AC and switching frequency 8 kHz.2) For rated current refer to table A.1 or table A.2!3) Connection of ext. braking resistor not permitted to devices with int. braking resistor (design G394-xxx-xxx-xx2)!4) Braking resistor always integrated. Connection of an external resistor is permissible.5) Option (G394-xxx-xxx-xx2)


NOTE: For more information on the braking chopper switch-on threshold also refer to section 3.14 from page 32.


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G394-020, G394-035 and G394-065

Designation

Technical data

G394-020 G394-035 G394-065

Output motor side 1)

Voltage 3 phase UMains

Continuous current effective (ln) 2) 2 A 3.5 A 6.5 A

Peak current (Aeffective) see table A.3

Rotating field frequency 0 ... 400 Hz

Switching frequency of power stage 4, 8, 16 kHz

Input mains side

Mains voltage (3 x 400 V AC / 3 x 460 V AC / 3 x 480 V AC) ±10%

Device connected load 1)

(with mains choke) 1.5 kVA 2.7 kVA 5.0 kVA

Current 1) (with mains choke) 2.2 A 3.9 A 7.2 A

Asymmetry of mains voltage ±3% maximum

Frequency 50/60 Hz ±10%

Power loss at IN 1) 42 W 80 W 150 W

1) Data referred to output voltage 400 V AC and switching frequency 8 kHz.2) For rated current refer table A.3!3) Connection of ext. braking resistor not permitted to devices with int. braking resistor (design G394-xxx-xxx-xx2)!4) Braking resistor always integrated. Connection of an external resistor is permissible.5) Option (G394-xxx-xxx-xx2)


Designation

Technical data

G394-020 G394-035 G394-065

DC link

Braking chopper switch-on treshold 650 V DC 1)

Minimum ohmic resistance of an externally installed braking resistor

230 Ω 180 Ω 3) 72 Ω 3)

Brake chopper continuous power with external braking resistor 1.8 kW 2.3 kW 5.9 kW

Peak brake chopper with external braking resistor 1.8 kW 2.3 kW 5.9 kW

Internal braking resistor 7500 Ω (PTC) 4) 420 Ω 5) 90 Ω 5)

Brake chopper continuous power with internal braking resistor 0 W depending on the effective load on the

drive in the specific application

Peak brake chopper with internal braking resistor 200 W 1) 1000 W 1) 4700 W 1)

1) Data referred to output voltage 400 V AC and switching frequency 8 kHz.2) For rated current refer table A.3!3) Connection of ext. braking resistor not permitted to devices with int. braking resistor (design G394-xxx-xxx-xx2)!4) Braking resistor always integrated. Connection of an external resistor is permissible.5) Option (G394-xxx-xxx-xx2)


NOTE: For more information on the braking chopper switch-on threshold also refer to section 3.14 from page 32.


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A.3 Ambient conditionsAmbient conditions MSD Servo Drive Compact

Protection IP20 except terminals (IP00)

Accident prevention regulations according to local regulations (in Germany e.g. BGV A3)

Mounting height up to 1000 m above MSl, over 1000 m above MSl with power reduction (1 % per 100 m, maximum 2000 m above MSl)

Pollution severity 2

Type of installation Built-in unit, only for vertical installation in a switch cabinet with min. IP4x protection, when using STO safety function min. IP54

Table A.6 Ambient conditions MSD Servo Drive Compact

Climatic conditions MSD Servo Drive Compact

in transit

as per EN 61800-2, IEC 60721-3-2 class 2K3 1)

Temperature -25 °C to +70 °C (-13 °F to +158 °F)

Relative air humidity 95% at maximum +40 °C (+104 °F)

in storage

as per EN 61800-2, IEC 60721-3-1 class 1K3 and 1K4 2)

Temperature -25 °C to +55 °C (-13 °F to +131 °F)

Relative air humidity 5 to 95%

in operation

as per EN 61800-2, IEC 60721-3-3 class 3K3 3)

Temperature

-10 °C to +45 °C (+14 °F to +113 °F) (4 kHz), up to +55 °C (+131 °F) with power reduction (2%per °C/°F)

-10 °C to +40 °C (+14 °F to +104 °F) (8, 16 kHz), up to +55 °C (+131 °F) with power reduction (2%per °C/°F)

Relative air humidity 5 to 85% witout condensation

1) The absolute humidity is limited to maximum 60 g/m³. This means, at +70 °C (+158 °F) for example, that the relative humidity may only be maximum 40%.

2) The absolute humidity is limited to maximum 29 g/m³ . So the maximum values for temperature and relative air humidity stipulated in the table must not occur simultaneously.

3) The absolute humidity is limited to maximum 25 g/m³. That means that the maximum values for temperature and relative air humidity stipulated in the table must not occur simultaneously.

Table A.7 Climatic conditions MSD Servo Drive Compact

Mechanical conditions MSD Servo Drive Compact

Vibration limit in transit

as per EN 61800-2, IEC 60721-3-2 class 2M1

Frequency [Hz] Amplitude [mm] Acceleration [m/s²]

2 ≤ f < 9 3.5 not applicable

9 ≤ f < 200 not applicable 10


Shock limit in transitas per EN 61800-2, IEC 60721-2-2 class 2M1

Drop height of packed device maximum 0.25 m

Vibration limit of the system1)

as per EN 61800-2, IEC 60721-3-3 class 3M1

Frequency [Hz] Amplitude [mm] Acceleration [m/s²]

2 ≤ f < 9 0.3 not applicable


1) NOTE: The devices are only designed for stationary use.

Table A.8 Mechanical conditions MSD Servo Drive Compact

ATTENTION!•No continuous vibrations!

The servo drives must not be installed in areas where they would be permanently exposed to vibrations.

•Control cabinet min. IP54 for STO! According to EN ISO 13849-2, when using the STO (Safe Torque OFF) safety function the switch cabinet must have IP54 protection or higher.

•Observe cooling conditions! Forced cooling by external air flow necessary. Air must be able to flow unhindered through the device (air flow at least 1.2 m/s). If a temperature cut-out occurs, the cooling conditions must be improved.

!


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A.4 Ul certificationThe devices are certified as per Ul 508C. For this purpose the following conditions are to be met by the user:

1. The devices may only be operated in systems of overvoltage category III.

2. The devices are rated for installation in an environment of pollution severity 2.

3. The protective device for branch lines must be executed in accordance with the manufcturers' instructions, the requirements of the NEC (National Electrical Code) and other locally applicable standards.

4. Only Ul certificated device connection cables (mains, motor and control cables) may be used:

− Use copper conductors with a temperature resistance of at least 75 °C (167 °F).

− Specified tightening torques for the terminals:

5. Maximum temperature of the ambient air (surrounding temperature): see table A.7

6. Multiple rated equipment: For details see tables A.1, A.2 and A.3.

7. Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacturer Instructions, National Electrical Code and any additional local codes.

8. Control outputs (X4/23; X4/24) and OSD00, OSD01, OSD02 (see ratings of control circuitry): Use secondary isolating source rated 25 V AC, 30 V DC or 24 V DC as appropriate for rating of the given output. Fuse in accordance with Ul248, rated 100 V must be connected between the source and the output.

9. Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical Amperes @ Volts maximum (+240 V maximum for G394-0xx / +480 Volts maximum for G394-0xx), when protected by class RK5 fuses:

Size DeviceTightening torque mains terminal X3

Tightening torque motor terminal X1

maximum mains fuse / class

C2

G394-030 5 - 7 lb-in (0.56 - 0.79 Nm) 10 A, 250 V / RK5

G394-020 5 - 7 lb-in (0.56 - 0.79 Nm) 6 A, 600 V / RK5

C3

G394-059 5 - 7 lb-in (0.56 - 0.79 Nm) 20 A, 250 V / RK5

G394-035 5 - 7 lb-in (0.56 - 0.79 Nm) 15 A, 600 V / RK5

C4

G394-080 4.4 - 5.3 lb-in (0.50 - 0.60 Nm)

7 lb-in (0.79 Nm) 25 A, 250 V / RK5

G394-065 4.4 - 5.3 lb-in (0.50 - 0.60 Nm)

7 lb-in (0.79 Nm) 20 A, 600 V / RK5

Table A.9 Tightening torques and mains fuse C2 to C4

Certifications

The MSD Servo Drive Compacts have the following acceptances:

Servo drive Certification

G394-030-xxx-xx1 Ul Recognized

G394-059-xxx-xx1 Ul listed


G394-020-xxx-xx1 Ul Recognized



NOTE: An Ul certification for dvices with integrated braking resistor (G304-xxx-xxx-xx2) is planned.


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Glossary

Symbole7-segment display .....................................................................................14, 152004/108/EC ..................................................................................................102006/42/EC ....................................................................................................102006/95/EC ....................................................................................................10

AAccident prevention measures.........................................................................13Ambient conditions ...................................................................................23, 51Analog inputs. see Control connections / Terminals; see also X4

BBacking plate ..................................................................................................11BGV A3 ............................................................................................................9Braking chopper .......................................................................................49, 50Braking resistor ...................................................................................31, 49, 50

Continous braking power ....................................................................32, 33Peak braking power .............................................................................33, 50

Button ................................................................................................14, 15, 39

CCable

Cable cross-section ....................................................................................22Cable length ..............................................................................................30Cable type .................................................................................................13Routing of cables .......................................................................................13

Cable length .................................................................................22, 30, 47, 48Circuit category ..............................................................................................10Climatic conditions .........................................................................................51

CoDeSys .........................................................................................................26Commissioning ...............................................................................................35Connection diagram .......................................................................................15Continuous braking power. see Braking resistor: Continous braking powerControl ...........................................................................................................37Control cabinet ...............................................................................................51Control connections / Terminals ...................................................24. see also X4Controlled shutdown. see Stop categories: Stop categorie 1 (SS1)Control supply ...........................................................14, 15, 21, 35. see also X2Control unit ....................................................................................................38Cooling ...........................................................................................................35

Cooling air .................................................................................................11Cooling conditions .....................................................................................11Heat ..........................................................................................................35

Creepages. see Clearances and creepagesCurrent capacity. see also Rated current

DD1, D2. see 7-segment displayDevice connected load ................... 49, 50. see Mains supply: Connection powerDevice error ........................................................................................38, 39, 43Device setting .................................................................................................40Diagnostics .........................................................................................25, 26, 43

Diagnostic interface. see Ethernet interfaceDigital in/outputs. see Control connections / Terminals; see also X4Dimensions .....................................................................................................12DIN EN 954. see EN ISO 13849DIN EN 1050. see EN ISO 14121DIN VDE 0100 ...................................................................................................9DIN VDE 0113 .................................................................................................10Display ........................................................... 21, 39. see also 7-segment displayMoog DriveADministrAtor ....................................................21, 26, 29, 36, 37, 44


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EElectrical isolation concept ..............................................................................20EMC

Effective EMC installation ...........................................................................16EMC-compatible installation ......................................................................11EMC Directive. see 2004/108/ECEMC product standard. see EN 61800

Emergency stop ..............................................................................................10EN 50014 .......................................................................................................10EN 50018 .......................................................................................................10EN 60204 .......................................................................................................10EN 61000 .......................................................................................................23EN 61508 .........................................................................................................9EN 61800 .....................................................................9, 10, 19, 21, 29, 43, 51EN 62061 .........................................................................................................9Encoder

Encoder cable ............................................................................................27Encoder connection ................................................................26. see also X6EnDat ..................................................................................................27, 29high-resolution encoder ....................................................14, 28. see also X7HIPERFACE® ........................................................................................28, 29Ready made-up encoder cable ...................................................................27Sin/Cos ..........................................................................................27, 28, 29SSI .......................................................................................................27, 29

EnDat. see Encoder: EnDatEN ISO 13849 ...................................................................................................9EN ISO 14121 .................................................................................................10ENPO ........................................................................................................24, 37Environmental conditions ................................................................................11Error code .......................................................................................................43Error number ..................................................................................................40EtherCAT. see Option 1Ethernet interface ............................................................14, 15, 26. see also X9

FFault currents (RCD) ........................................................................................23Fieldbus

Fieldbus address...................................................................................38, 42Fieldbus options. see Option 1Fieldbus settings ........................................................................................38

FilterFrequency interference suppression filters ..................................................16Mains filter ................................................................................................18

For your safety ..................................................................................................9Fuses. see Mains supply: Mains fuses

GGrounding. see Grounding leadGrounding lead ...........................................................................................9, 19

Connection PE conductor ..........................................................................19

HH1 (monitoring lED) .................................................................................13, 14Hazard class ....................................................................................................10Helpline/Support & Service ..............................................................................44High-resolution encoder. see Encoder: high-resolution encoderHIPERFACE®. see Encoder: HIPERFACE®How to use this document ................................................................................3

IIEC 364 .............................................................................................................9IEC 60721 .......................................................................................................51IEC 60755 .......................................................................................................23IEC 61131 .......................................................................................................26IEC 61800 .................................................................................................16, 23Industrial .........................................................................................................16Initial commissioning ................................................ 35. see also Commissioning


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Installation ................................................................................................13, 16Integrated control unit. see Control unitIntended use ...................................................................................................10Interference immunity .....................................................................................16IP address .................................................................................................38, 40ISDSH .......................................................................................................25, 37IT-Net ..............................................................................................................23

llayout ............................................................................................................14leakage current ..............................................................................................18low Voltage Directive. see 2006/95/EC

MMachinery DirectiveMains choke ...................................................................................................23Mains filter. see Filter: Mains filterMains supply ...................................................................................................21

Connected load .........................................................................................23Mains connection ...................................................................18. see also X3Mains fuses .........................................................................................23, 52

Mechanical conditions ....................................................................................51Mechanical installation ....................................................................................11Motor

Motor brake .............................................................14, 15, 25. see also X13Motor cable ...............................................................................................17Motor connection .............................................................29, 30. see also X1Motor dataset ............................................................................................36Motor temperature monitoring .........................................14, 15. see also X5Motor temperature sensor. see also X5

Klixon ....................................................................................................28KTY .......................................................................................................28PTC ..................................................................................... 27–31, 49, 50

Ready made-up motor cable ......................................................................30Servo motor ...................................................................................26, 27, 30

Mounting. see Mechanical installation

NNational Electrical Code. see Requirements of NECNeutral point ..................................................................................................23Notes for operation .........................................................................................11

OOption 1 .............................................................................................14, 15, 26Option 2 ..........................................................................14, 15, 26. see also X8Order code .......................................................................................................4Overvoltage category ................................................................................23, 52

PParameter setting ........................................................38. see also Device settingPE. see Grounding leadPeak braking power. see Braking resistor: Peak braking powerPictograms ........................................................................................................5Pollution severity .............................................................................................52Power connection ..................................................................14, 30. see also X1Power stage ..........................................................24, 29, 31, 33, 37, 43, 49, 50Power stage ready ..........................................................................................49Project planning ..............................................................................................44Protection .......................................................................................................33Protective extra-low voltage ............................................................................20

QQualification .....................................................................................................9


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RRadio frequency interference suppression filter. see Filter: Radio interference suppression filterRated current ........................................................................................4, 47, 48Rating plate ................................................................................................4, 44Requirements of NEC ......................................................................................52Residential ......................................................................................................16Residual current operated protective device.....................................................23Resolver ....................................................................................................27, 28

Resolver connection ................................................................28. see also X6Responsibility ..................................................................................................10Risk .................................................................................................................10

Risk analysis ...............................................................................................10

SSafety

Notes of safety ..........................................................................................35Safety Function ..........................................................................................45

Safety extra-low voltage ..................................................................................20Safety function ...............................................................................................37SERCOS. see Option 1Serial number .............................................................................................4, 44Service. see Helpline/Support & ServiceService interface. see Ethernet interfaceShield connecting plates ...................................................................................4Shielding

Shielding measures ....................................................................................13Shielding measures .........................................................................................13Sin/Cos. see Encoder: Sin/CosSpecification of control connections ................................................................24Specimen setup ..............................................................................................16SSI. see Encoder: SSIStart-up current ..............................................................................................21

STO .............................................37. see Stop categories: Stop category 0 (STO)ISDSH ........................................................................................................37STO ...........................................................................................................37

Stop categoriesStop category 0 (STO) .......................................................................... 24–25

Subnet mask ...................................................................................................41Supply package .................................................................................................4Supply voltage ................................................................................................21Support. see Helpline/Support & ServiceSwitching frequency ...........................................................................21, 49, 50Switching frequency change ...........................................................................48Switching in the motor cable ..........................................................................31Switching on frequency ..................................................................................37Switching on sequence ...................................................................................37Symbols. see Pictograms

TTCP/IP interface. see Ethernet interfaceTechnical data .....................................................................................23, 33, 49Technology options. see Option 2Temperature evaluation ...................................................................................29TN network .....................................................................................................23TT network .....................................................................................................23

UUl certification ................................................................................................52Uncontrolled shutdown. see Stop categories: Stop category 0 (STO)

VVariant ............................................................................................................26Vicinity............................................................................................................35


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WWall mounting ................................................................................................11Warning symbols ............................................................................................10

XX1 ..................................................... 14, 15, 17, 52. see also Power connectionX2 ...........................................................14, 15, 17, 21. see also Control supplyX3 ................................14, 15, 18, 52. see also Mains supply: Mains connectionX4 ...........................14, 15, 18, 24, 25. see also Control connections / TerminalsX5 ............................14, 15, 29. see also Motor: Motor temperature monitoringX6 ..............................14, 15, 27, 28, 29. see also Resolver: Resolver connectionX7 ........................ 14, 15, 27, 28, 29. see also Encoder: high-resolution encoderX8 ............................................................................... 14, 15. see also Option 2X9 ................................................................. 14, 15. see also Ethernet interfaceX13 ...................................................... 14, 15, 25. see also Motor: Motor brake


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Technical alterations reserved.

The contents of our documentation have been compiled with greatest care and in compliance with our present status of information.

Nevertheless we would like to point that this document cannot always be updated parallel to the technical further development of our products.

Information and specifications may be changed at any time. For information on the latest version please refer to [email protected].

Id no.: CA97555-001, Rev. 3.0

Daste: 06/2012

Applicable as from firmware version: V0.25

The German version is the original of this Operation Manual.

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